Challenges and Solutions in the Recycling Industry

Challenge ➢ Consistent throughput despite fluctuations in recycled material

Recycled materials often vary more widely than virgin materials. Differences in bulk density, particle size distribution (flakes/ground material/granules), moisture content, or abrasion can lead to uneven material flow, pulsations, and unstable throughput rates. This increases the effort required for readjustment, scrap, and downtime—and narrows the process window.

In continuous applications in particular, such fluctuations have an immediate impact: dosing deviations can alter mixing ratios, additive proportions can drift, and the overall process becomes unstable. Robust production therefore requires a control system that detects actual process changes and actively compensates for them.

The DEMIC Solution

Gravimetric dosing based on the “loss-in-weight” principle continuously measures the actual mass flow and automatically compensates for material fluctuations. DEMIC offers tailor-made solutions for the continuous dosing of bulk materials and powders.
The DE-CONscrew dosing controller supports the operation of differential scales for dosing bulk materials and powders using dosing screws—including continuous performance monitoring and automatic performance adjustment.

Challenge ➢ Precise additive dosing with a fluctuating main flow

In recycling, additives, stabilizers, color masterbatches, and processing aids are often crucial for stabilizing recycled materials and achieving specific properties. At the same time, the main material stream fluctuates more frequently—making it challenging to ensure precise, reproducible additive dosing. Even minor deviations can affect color, mechanical properties, or processability.

In addition, frequent material changes (different recycled material fractions, formulations, target qualities) increase the effort required for process control. Changeovers and run-in phases should be kept short—without compromising dosing accuracy.

THE DEMIC SOLUTION

High-resolution weight measurement and dynamic control enable precise dosing even with fluctuating raw materials. DEMIC dosing systems are specifically designed for gravimetric and volumetric dosing of powders and granules and can be combined as needed depending on the application.
For batch applications, DEMIC offers control solutions for batch weighing (e.g., cumulative weighing/gain-in-weight)—suitable for everything from very small quantities to larger batches.

Solutions: Intelligent dosing and control technology for stable recycling processes

For robust recycling processes, dosing, weighing, and control technology are crucial—technology that does not “amplify” fluctuations in the input but actively compensates for them. Gravimetric systems measure the actual material mass and stabilize the mass flow—which is particularly important when bulk density and flow behavior vary.

With the modular DEMIC approach, continuous dosing and batch weighing can be adapted to the specific production line—including controllers, load cell measurement, drive technology, and operator interfaces. This creates stable process windows, improves reproducibility, and reduces scrap and downtime.

Ansprechpartner von DEMIC Datentechnik GmbH

Your Contacts

Björn Demmer

Partner - Managing Director

PHONE: 02247 918 90
EMAIL: bdemmer(at)demic-datentechnik.de

Heinz Demmer

Partner - Managing Director

PHONE: 02247 918 90
EMAIL: hdemmer(at)demic-datentechnik.de

FAQs About the Recycling Industry

Because fluctuations in recycled material quality directly affect the formulation, material properties, and process stability—precise dosing keeps target values stable.

Gravimetric dosing measures the actual mass and can better compensate for fluctuations in density and flow behavior—which is particularly important when the input varies.
 

DEMIC offers solutions for the continuous dosing of bulk materials and powders (as well as pastes and liquids in general, depending on the application).

The mass flow is determined and controlled based on the weight loss at the dosing system—any deviations are continuously compensated for.

Through continuous performance monitoring and analysis, performance can be automatically adjusted—ensuring more stable dosing of bulk materials and powders.
 

Yes, depending on the design: There are universal dosing systems for volumetric and gravimetric dosing of powders and granules.

When defined batches or formulations are to be created (e.g., additive packages/mixtures)—including multi-component weighing.
 

Raw materials are added one after another to a scale and processed using weighing technology (cumulative weighing).

About configurable control and operating concepts and a control system that stably adapts to new material properties.

DEMIC focuses on comprehensive, modular system solutions for dosing equipment and control technology—which often makes integration possible depending on the interfaces and processes involved.